Manufacture of iron and steel.



N0.7`85,Q02. l PATENTEDMAR-14, 1905.

' .J.J.HUDSON.

MANUFACTURE 0F IRON AND STEEL.

APPLIOATIQN FILED 1mm, 1904.

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' 'raw' t' UNITED STATES .Patented March 14, 1905.

PATENT OFFICE.

JAMES JONES HUDSON, OF PHILADELPHIA,PENNSYLVANIA.

IVIANUFAGTURE OFiIRON AND STEEL.

SPECIFICATION forming part of Letters Patent N0. 785,002, dated March 14, 1905. u i Application filed March 9, 1904. Serial No. 197,212. l

To {,r/ZZ wl/1,0111, it 71mm/ concern:

Y Be it known that I, JAMES J oNEs HUDSON, a citizen of the 'United States, residing in Philadelphia, Pennsylvania. have invented certain Improvements in the Manufacture of Iron and molten condition,at the same time introd ucing blasts of air to the molten'metal for the purpose of boiling it, which method of procedure has the effect of refining such iron by decal'- burization and oxidation, the metal ltering through the charcoal and the latter consuming the impurities as they are eliminated from the molten mass. In some instances I may add some charcoal to the metal after it has reached a molten condition to insure the combustion and dissipation of any injurious gases arising during the boiling operation.

My improved process of manufacturing charcoal-iron may be applied to the manufacture of charcoal-steel with equally-valuable results.

The process forming the subject of my invention may be carried out in furnaces of different character, and as illustrating one type of furnace capable of carrying my invention into effect reference is had tothe accompanying drawings, in which- Figure l is asectional plan View of said furnace. Fig.2is a longitudinal sectional View on the line a c, Fig. 1. Fig. 3 is a cross-sectional View on the line b L, Fig. 2; and Figs. 4 and 5 are views of an adjustable twyer.

In the old or common process of manufacturing charcoal-iron the method of procedure is as follows: Metal from arun-out fire, scrap, or other suitable or convenient material to the amount of two hundred and fifty to three hundred pounds, together with charcoal, is

thrown at one charge into an open, nobbling, or sinking fire, and in this fire it is formed into what is variously known as a masse, bloom,'lump, or loupe, hereinafter referred to as a loupe. As the metal melts it falls to the bottom of the furnace and cools, and in leaving the heated zone of the furnace it frequently carries portionsof raw or unmelted iron with it. raw addition to the metal, the forgeman is obliged to Araise theV mass with a suitable bar, so as to bring it back to the highly-heated part of the furnace. This requirement, as may be .readil-yunderstood, is laborious, uncertain,

and costly, and it is impossible to produce a perfect homogeneous metal of standard grade. The run-out fires, however, have been generally abandoned because too expensive, so that the material used for the chargeis iron and steel scrap of all grades, such as are on the market to-day, and I may here state as one of the primary and principal defects of the old process that the small amount of refining this material gets in sinking in the old-fashioned fire, as just explained, isA not sufficient to change it to any great degree, so as to produce a pure and homogeneous iron. From the nobbling-fire the loupe is taken to the hammer I to be shapedfor the muck-rolls. Before going to the rolls, however, the bloom.7 (.as it is now called) is reheatedin a heating-furnace and then taken to the mill to be rolled out into what arecalled charcoalmuckbars. When cold, these bars are cut in pieces the length of which depends on the weight of pile desired, which is generally live or siX barshigh. These bars are again put in the heating-furnace and afterward rolled into plates, boilertube skelp, barsfor tin-plate, or any other shape for which charcoal-iron is used.

The defects of the old process are quite numerous, some of which are as follows: As the metal sinks through thev mass of fuel pieces of scrap or raw iron will sink into the softer part of the loupe without being refined, and pieces will also stick to the surface of the loupe and be hammered in, acondition which will result in the iron containing flaws and blisters. One forgeman might by chance make a fairly good loupe, while the forg'eman on the next fire might make an inferior one, and when cut in pieces for the bars to pile the inferior bars will spoil the good ones. Also a pile would be made up of bars of different makes-z'. e., of different analysesso that there would be no uniformity of quality. In heating the bars it is necessary to have a good Welding heat in order to properly weld them, for if not properly welded they will show up in flaws and blisters. On the other hand,'if the heater produces too high a heat, which he is apt to do, and burns such bars the nature of the iron is destroyed. Another defect which very often occurs is that occasioned by some unavoidable delay in taking the loupe from the fire, causing carburization. These objections all tend to lead tol the abandonment of weldable iron, as by the old process it is impossible to obtain a pure and homogeneous metal. According to my improved process, however, which I will now proceed to describe, I do away with the preliminary forging and shaping of the mass of metal and run the molten metal, after it has been refined and brought-to the proper analysis, directly into a suitable mold, from which it may be taken as soon as it has received asuri face chill, given a wash haat in a suitable furnace or oven, and then passed directly to the mills to be rolled into skelp, plates, or other suitable shapes.

The mixture for a high grade of charcoaliron made in accordance with my invention may be as follows, supposing it is desired to make fifteen tons: iron ore, one ton; cast and pig iron, six tons; wroughtiron and' steel scrap, eight tons. For this amount of metal about fifteen bushels of charcoalj per ton of other material will be required.

In carrying out my improved process I may use any suitable form of furnace, and in the present instance I have shown a simple form of melting-furnace capable of carryingiA out my improved process.

In the drawings the furnace-body is show at 1 with feed-openings 2, a tap-hole 3, closed by a plug 4, and twyer-openings 5, in which are mounted the twyers 6. At the ends of the furnace the pipes 10 are provided, which discharge gas, oil, or a suitable hydrocarbon vapor that is ignited and serves to heat the furnace. vThe bed of the furnace is indicated at 11, and the layers of charcoal and metal are shown in the preferred method of charging the furnace, being indicated at 12 and 13, respectively, Figs. 2 and 3. In Figs. 1 and 3 the feed-openings are shown closed by doors 14, and the furnace is supposed to be in condition to melt the metal. During this action the products of combustion, will pass out through the end opening 15 to any suitable discharge-outlet. After the metal is melted, maintained in the molten condition, land refined to the proper degree the plug 4 may be A form of adjustable twyer for use with the melting-furnace I have shown for carrying out my invention is fully illustrated in Figs. 4 and 5. The twyer-opening 5 is in the form of a conical recess with its smallest end opening into the melting-chamber. The twyer 6 is adjustable up and down inthis recess by thefollowing means: Extending rearwardly from the bottom of thetwyer is a projection 20, which is connected to a stirrup 21, hung from a threaded stem 22. Carried by the side of the furnace is a supportingbracket 23, carrying a threaded bolt 24, and a turnbuckle 25 is used for connecting these threaded members. i B y operating this turnbuckle the stirrup may be raised and lowered, and with it the twyer. To guide the twyer in its vertical movement, I provide the side plates 26, which are slotted at 27 to receive the ends of a bolt or ba'r 28, carried by the stirrup. This slot is curved in the arc of a circle struck from the point of contact of the twyerwith the inner wall of the furnace. A blast-pipe 30 is connected to the twyer by means of a iexible section 31, which may be of leather or any suitable substance commonly used for the purpose, and the water-pipes 32, two -in number, are also connected to the twyer by means of flexible sections 33. These flexible sections provide for ready connection of these members and at the same time permit a Wide range of adjustment for the twyer.

The furnace. of whatever design employed, is charged with the scrap, pig-iron, and ore to the amount of fifteen tons, with the proper addition of charcoal, and the twyers,which are y preferably adjustably mounted, as just described, or other means of discharging air under pressure to the charge are set so as to deliver the air-blast through the mass of mate` rial. Before charging the furnace, however, it is preferably brought to a proper heat by any suitable means--by preference gas, hydrocarbon vapor, or oil discharging from the pipes 10, (although in some instances I may use coal`)-and then the charge is inserted and melted and kept in a molten condition, charcoal being added to increase the heat and continue the refining. While in this molten condition it will be boiled and thoroughly refined by means of the charcoal, air-blast, and other source of heat, eliminating sulfur, phosphorus, silicon, and other injurious ingredients to an extent hitherto unknown in the manufacture of iron and steel, the mass being decarburized until the analysis of the molten metal which may be made from time to time shows the quality of iron required, thereby enabling me to produce any desired uniform grade of charcoal iron or steel. The resultant metal will be found to be of superior quality and of the greatest value in the manufacture IOO of boiler tubes and plates, and as soon as its analysis shows the quality desired it is drawn from the furnace into masses of different shape and size, according to the kindof iron to be rolled, and after it has received a surface chill it is given a wash heat in a suitable furnace or oven and may then be passed directly to the mill, where it is rolled into plates, slielp, oi' bars for tin-plate or any other suitable shapes.

For a cheap grade of charcoal-iron I may increase the quantity of iro: n ore and castscrap and pig-iron and besides reducing the quantity of wrought and steel scrap l may use a cheaper grade of scrap and add only about twelve bushels of charcoal to each ton of the mixture. While Iprefer to use cold air for the blast in most instances in producing the cheaper metal, I may employ a blast of heated air, as this enables me to use a less amount of the charcoal fuel.

My improved process of using charcoal in the manufacture of charcoal-iron may alsobe used to advantage in the manufacture of steel. Mild steel is at present used because of its relative cheapness for many purposes for which charcoal-iron should be used. I propose to 'refine such steel by the use of charcoal, and thereby render it available for all purposes for which cliarcoal-iron of the best grade is available. I may do this in a furnace similar to the one shown for carrying out my improved charcoal-iron process, although it will be understood that I may use any suitable form of melting-furnace having provision for heating the same by oil, gas, or hydrocarbon fuel and for introducing air in blasts through suitable twyers, preferably adjustably mounted. After thoroughly reiining the mass by means of the charcoal, eliminating the injurious elements, I recarbonize it with accuracy and producea pure and high-grade steel.

For a mixture of fifteen tons of steel I may use the following proportions: wrought-iron and steel scrap, nine tons; pigeiron, siX tons. For this amount of metal aboutfifteen bushels of charcoal per ton will be required. After the metal is melted its subsequent treatment may be similar to the treatment of the charcoal-iron just descibed.

The advantages of my improved process of manufacturing charcoal iron and steel are as follows: The resultant metal contains no pieces of scrap or raw iron sunk into the same unrefined. Hence I produce a perfect iron and steel of higher grade than that which is produced by the old process. I do away with the preliminary forging and shaping of the mass of metal and rolling the same into muck-bars. In the old process too much depends on chance, because there is no way of taking an analysis, and even with conscientious care and effort on the part of the workmen they cannot prevent defects in the iron lduce a metal of high grade. charcoal, however, the molten metal in passing or insure a homogeneous product, while with the improved process forming the subject of my invention charcoal-iron or charcoal-steel can be produced with any analysis the trade may require. Besides producing a homogeneous iron and steel and of a high grade another advantage of my process is a considerable reduction of cost, making it possible to put on the market metal that is reliable at a price that will encourage its use for purposes where the superiority of charcoal-iron is unquestioned. While the melting of iron or steel and the continuance of such metal in a molten condition will refine it to a certain extent, there are certain impurities that will not respond to this treatment to a degree suflicient to pro- VVitli the use of through it leaves behind its impurities, which are consumed by the charcoal, the latter hav- 4ing a certain affinity for this action .not obtainable when the metal is melted and boiled in the ordinary manner.

Having thus described my invention, I claim and desireto secure by Letters Patent- 1. The improvement in the art of manufacturing iron and steel, which consists in placing Aa combined charge of charcoal and the material to form such metal upon the hearth or bottom of a furnace, melting said metal with the charcoal, and maintaining a molten bath ofthe metal in contact with the charcoal until the completion of the heat.

2. The improvement in the art of manufac- 4 turing iron and steel, which consists in placing a combined charge of charcoal and the material to form such metal upon the hearth or bottom of a furnace, heating said furnace to a temperature suiiicient to melt said metal with the charcoal. and maintaining a molten bath of the metal in contact with the charcoal until the completion of the heat.

3. The improvement in the art of manufacturing iron and steel, which consists in placing a charge of charcoal upon the hearth or bottom of a furnace, placing' material to form such metal upon said charcoal, melting said metal with the charcoal, and maintaining a molten bath of the metal in contact with the charcoal until the completion of the heat.

4. The improvement in the art of manufacturing iron and steel, which consists in heating a suitable furnace, placing a charge of charcoal upon the hearth or bottom of the IOC to raise the heat of the furnace and melt the A metal, and then maintaining said metal in a molten bath in contact with the charcoal until the completion of the heat.

5. The improvement in the art of manufacturing iron and steel, which consists in heating a suitable furnace, placing a charge of charcoal upon the hearth or` bottom of the same, placing a charge of iron upon said charcoal, introducing a blast of air to raise the temperature suficiently to melt and refine said charge, and maintaining a molten bath of the metal in contact with the charcoal until the completion of the heat.

6. The improvement in the art of manufacturing iron and steel, which consists in heating a suitable furnace, placing a charge of charcoal and iron upon the hearth or'bottom of the same, introducing a blast of air to increase the heat and melt said charge, and then maintaining a molten bath of the metal in contact with the charcoal until the completion of the heat.

7. The improvement in the art of manufacturing iron and steel, which consists in heating a suitable furnace, placing a charge of charcoal and iron upon the bottom or hearth of the same, introducing a blast of air to increase the heat and effect the melting of the y charge, and maintaining said blast until the iron is caused to boil in the presence of the charcoal whereby it may be refined by the charcoal and maintained in a molten condition in Contact therewith until the completion of the heat.

8. The improvement in the art of manufacturing charcoal iron and stecl of uniform gradeV or quality, w-hich consistsin heating a suitable furnace, placing a charge of charcoal and iron upon the hearth or bottom of the same, introducing a blast of air to increase the heat of the furnace and thereby melt the metal, maintaining such metal in a molten conditin in the presence of the charcoal whereby it may be refined by the same until the metal shows the analysis desired, such process being carried on in such a manner as to permit testing and analysis of the metal from time to time, and then casting said metal substantially as described.

9. The improvement in lthe art of manufacturing charcoal iron and steel, which consists in heating a suitable furnace, charging the same with alternate layers of charcoal and iron, introducing a blast of air to assist the combustlon and raise the melting heat, and

maintaining a molten bath of the metal in contact with the charcoal until the impurities of the metal are burned out and the heat has been completed.

10. The improvementin the art of manufacturing charcoal iron and steel, which consists in heating a suitable furnace, charging the same with alternate layers of charcoal and iron, introducing a blast of vair to assist the combustion and raise the melting heat, maintaining said metal in a molten condition in contact with the charcoal, and finally boiling it until the impurities of the metal are burned out and the heat has been completed.

11. The improvement in the art of manufacturing charcoal iron and steel, which consists.

in heating a suitable furnace, charging the same with alternate layers of charcoal and iron, introducing a blast of air to assist the combustion and raise the melting heat, maintaining said metal in a molten condition until the impurities of the metal are burned out by the charcoal, causing said molten metal to boil, and then adding a suitable fuel to the metal to burn off the gases arising during the boiling operation until the metal shows the analysis desired.

12. The improvement in the art of manufacturing iron and steel, which consists in heating a suitable furnace, placing a charge of charcoal and iron upon the hearth or bottom of the same, melting said metal, introducing a blast of air to increase the heat and cause said charge to boil thereby refining the metal with the charcoal, and then finishing the boiling to bring the metal to the analysis required by the means for heating the furnace such as the gas, hydrocarbon vapor, or oil fuel, substantially as described.

In testimony whereof I have signed my name to this specification in the presence of two subscriblng witnesses.

J. JONES HUDSON.

Witnesses:

MURRAY C. BOYER, Jos. H. KLEIN. 

